3D Intelligent Rubber Production Structure
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Solution Overview
Problem
The existing molding vulcanization process for rubber products is limited by the need for increased mold cavity capacity, which complicates the mold structure and increases costs, reducing automation and flexibility.
Innovation Solution
A 3D-configured production structure based on an intelligent manufacturing unit, comprising a stereoscopic production warehouse and an ex-warehouse delivery system, with a mobile intelligent manufacturing unit that includes a molding vulcanization apparatus, a blank feeder, a material-delivering apparatus, a product-collecting apparatus, and a reclaimer, allowing for flexible and automated production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the mold cavity is increased to increase production capacity, then the production capacity is improved, but the mold structure becomes more complicated and the overall volume of the mold increases
Solution Approach 1:
The patent divides the production system into multiple independent intelligent manufacturing units, each capable of autonomous operation. Instead of increasing the complexity of a single large mold, the system uses multiple smaller modular units that can be independently controlled and maintained, thereby increasing overall production capacity without complicating individual mold structures.
Solution Approach 2:
The patent transitions from a traditional 2D mold cavity expansion approach to a 3D spatial arrangement of multiple intelligent manufacturing units. By stacking and arranging units in three-dimensional space with automated vertical material delivery, the system increases production capacity through spatial utilization rather than expanding the footprint or complexity of individual molds.
2Productivity
If the mold cavity is increased to increase production capacity, then the production capacity is improved, but the processing cost increases
Solution Approach 1:
The patent segments the production system into standardized intelligent manufacturing units that can be manufactured independently and assembled. This modular approach reduces processing costs by enabling specialized manufacturing of each unit, simplified maintenance, and the ability to replace or upgrade individual units without redesigning the entire system.
Solution Approach 2:
The intelligent manufacturing units are designed with universal interfaces and standardized configurations that allow them to perform multiple functions. Each unit can handle different rubber products through programmable control, reducing the need for specialized expensive molds for each product type and lowering overall processing costs.
3Productivity
If the mold cavity is increased to increase production capacity, then the production capacity is improved, but the automation and flexibility are reduced
Solution Approach 1:
The patent implements dynamic, programmable intelligent manufacturing units with PLC controllers that can adapt to different production requirements. Each unit is equipped with sensors, automated material handling, and programmable logic to perform autonomous operations, thereby increasing both automation level and flexibility simultaneously rather than sacrificing one for the other.
Solution Approach 2:
The intelligent manufacturing units are designed to be self-sufficient with integrated material storage, automated material delivery systems, and self-monitoring capabilities. Each unit can independently manage its own production cycle, reducing the need for complex centralized control systems and enabling higher automation with greater flexibility.
4Productivity
If the mold cavity is increased to increase production capacity, then the production capacity is improved, but the flexibility is reduced
Solution Approach 1:
The patent segments the production system into independent modular units that can be individually configured and programmed for different product types. This segmentation allows the system to maintain high overall production capacity while providing flexibility at the unit level, as each module can be independently adjusted or reassigned to different production tasks.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enhances production flexibility and automation, reducing the complexity and cost of mold design while increasing production capacity and efficiency.
Implementation Method 1
the middle of the upper heat plate is provided with a heat pipe used to provide heat
Implementation Method 2
an air hole channel used to provide force to adsorb a mold
Implementation Method 3
a vulcanization cylinder is fixed on the lower side of the fixing plate, the output end of the vulcanization cylinder is connected and fixed to the lower heat plate
Data Source
AI summary
A 3D-configured production structure of rubber products based on an intelligent manufacturing unit and a production method thereof. The structure includes a stereoscopic production warehouse used to store a mobile intelligent manufacturing unit and an ex-warehouse delivery system used to deliver the mobile intelligent manufacturing unit. The mobile intelligent manufacturing unit includes a unit functional assembly, a molding vulcanization apparatus, a blank feeder, a material-delivering apparatus, a product-collecting apparatus and a reclaimer. The molding vulcanization apparatus includes a upper heat plate, a upper mold, a lower mold, a lower heat plate and a support post. The upper mold and the lower mold are arranged on the inner sides of the upper heat plate and the lower heat plate, respectively. The upper heat plate is fixed on one end of the support post, and the lower heat plate is arranged through the support post.